Monadnock Sustainability

Second edition

A Field Guide

Eco-Friendly, Efficient and Effective Print

Second edition

A Field Guide

Eco-Friendly, Efficient and Effective Print

die cut

In This Field Guide: Paper

2

Production

13

Inks

18

Printing

21

Finishing

25

Packaging

26

Checklist

30

Reference

32

Commitment Today

33

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient and Effective Print

Eco-Friendly by Design Print is an enriching medium that is resource intensive. When we use those resources efficiently before, during, or after production, we can reduce the size of our footprint on the natural world. In die cut

today’s climate of growing social and fiscal responsibility, designers and printers are adapting design and business practices to conserve resources and lessen overall impact on the environment. The purpose of this guide is to offer information in support of sustainable design and print. The message is threefold: Eco-friendly design can be cost-efficient, environmentally sensitive and beautiful. This guide gives graphic professionals the opportunity to think about design differently.

Introduction • 1

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Paper • 3

Virgin paper | Coming directly from trees, it contains the

Recycled content can be any

strongest and purest fiber and requires the most energy to

blend of recycled paper fiber

manufacture. It obviously has the most immediate impact on the

and may also contain virgin

forest. However, that impact may be mitigated if the pulp is harvested

paper fiber.

from a source that is part of a forest sustainability program. Its

Pre-consumer waste

first-generation status means that virgin paper has not undergone prior printing, which can make it the most chemical free depending on its bleaching process. When specifying virgin paper, care should be taken to ensure that the pulp comes from a sustainable source. Designers should include a note to end users encouraging recycling of printed pieces made with virgin paper.

from unsold magazines

fiber now provides almost 37% of the domestic raw material used to

and periodicals.

fiber (TRF), or various blends of each. Recycled paper has dramatically improved in quality over the past decade, in most cases performing as well as virgin stock and has become cost competitive.2

made with recycled materials. Use of the recycling logo is not regulated by law; however, the Federal Trade Commission does offer guidelines. Claims should be made in language that makes the environmental attributes clear. In addition to recyclability, claims can be made regarding content and

used by a consumer and often that occur in manufacturing or

pre-consumer waste, post-consumer waste (PCW), totally recycled

package is recyclable and/or

or printer. It has never been

lows the same fiber to be used and reused many times over. Recovered

emissions in manufacturing than virgin paper. Content may include

indicates that a product or

waste at a mill, fabricator and/

Recycled paper | Use of this has grown substantially. Recycling al-

and landfills. Recycled paper uses less energy and produces fewer

Recycle logo | This

fiber that was recycled from

is derived from the trimmings

make paper products,1 which has helped reduce the pressure on forests

Paper

content paper contains

Post-consumer waste (PCW) content paper contains fiber that has been in circulation in finished form and has been recycled by the end user. It is considered the most environmentally efficient since

A printed piece or package can be labeled as recyclable only if it

it has had at least one useful

can be recovered from the solid waste stream for reuse through an

life before returning to service.

established recycling program. Claims do not have to be qualified

Papers with the highest post-

The manufacture of paper requires the use of natural resources.

if the entire piece is recyclable. Otherwise, state how much or what

consumer waste content are

How much and how efficiently those resources are used depend

specific components can be recycled. Paper suppliers and printers

the most eco-friendly.3

quite a bit on the processes manufacturers use in resource acquisi-

will have this information. The claim of recycled content can be

tion and production. By obtaining tree fiber from sustainable

made only on products manufactured from materials recovered

sources, by using water judiciously and responsibly and by making

during the manufacturing process (pre-consumer) or after they

greener energy choices, manufacturers and their suppliers can

have served their intended purpose (post-consumer). The Federal

drastically reduce the size of their environmental footprint. Over

Trade Commission stipulates that the distinction be made between

the last several decades, foresters, environmentalists and paper

pre-consumer and post-consumer content (see example below).

Totally recycled fiber (TRF) content paper contains 100% recycled material and may contain pre- and postconsumer content.

manufacturers have made great strides to protect forestland and wildlife habitat, manage natural resources for sustainability and maintain air and water quality. Designers can make a difference by

How to Communicate Paper Contents

choosing manufacturers who subscribe to these best practices.

Recycled content is often expressed in an equation

processing (for example, to

Paper is manufactured with a variety of fiber content. Some fibers may

note soy ink content or the use

be virgin and various blends of recycled paper, some may be totally

of chlorine-free processing).

recycled content and some may be post-consumer recycled content.

Example:

denoting its percentage of content. It is generally labeled with the total amount of recycled content first

(100% recycled content, of which

and the amount of post-consumer material second.

30% is post-consumer waste)

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Paper • 5

and buffered papers offer a longer life and should be considered

It has been argued that the

for projects that require longevity.

added energy consumed in

For many years, elemental chlorine was used to bleach pulp to make it white and improve paper strength, absorbency and softness. This process created a hazardous byproduct which adversely affected aquatic ecosystems throughout the world. Today, most North American and European pulp mills have found alternative, environmentally safe methods for bleaching pulp. Process Chlorine Free (PCF) | The PCF designation indicates that no chlorine or chlorine compounds were used in the pulp

the recycling process minimizes any savings in the use of recycled paper versus virgin paper. However, assessments8 by Environmental Defense and the Alliance for Environmental Innovation reveal clear environmental benefits to recycled paper:

and papermaking processes. PCF fibers have not been re-bleached with chlorine-containing compounds, though some chlorine may remain from the manufacture of the source material.

27% less energy consumption

Elemental Chlorine Free (ECF) | ECF is a designation for virgin paper that uses a chlorine derivative (usually chlorine dioxide) instead of elemental chlorine for

47% fewer greenhouse gases

whitening in the pulping process. ECF pulp has become the most widespread replacement for elemental chlorine pulp to date, and Tree Free | Nearly 40% of the trees cut in North America are used for paper production.4 An alternative to wood pulp is plant fiber—either agricultural residue recovered from crops or fibers

Coated papers, as a group, are harder to recycle because of the clay coating that gives the papers their shiny, smooth surfaces. Forty percent 6

less fiber is extracted from

produces paper with the same tactile qualities, strength and European Commission recognize it as “Best Available Technology.”9

harvested from plants grown intentionally for tree-free paper.

Totally Chlorine Free (TCF) | The TCF label, designated for

The most common are kenaf, hemp, flax, cotton and combina-

virgin fiber papers, indicates that no chlorine or chlorine

tions thereof. In addition to their environmental value, plant fiber

compounds were used in the pulping process. Thanks to recent

papers—especially kenaf and hemp, with their combination of

process improvements, many TCF papers now approach the

long and short fibers—tend to be more durable.5 Containing less

brightness levels of ECF papers.

www.papercalculator.org,

percent cotton paper has low acidity and is frequently used for

a website operated by

archival purposes.

Environmental Defense.

Archival | Buffering agents added in the papermaking process can absorb acids from external contaminants and any residual acids in the paper. Acids can dramatically affect the life

has a different look and feel,

span of papers by breaking down the cellulose fibers and making

a premium uncoated post-

the paper yellow and brittle. A truly “archival” sheet of paper

consumer-waste paper can

is acid free (alkaline pH) and is usually buffered with calcium

yield excellent-quality results in

carbonate to stabilize the level of alkalinity. This protects the paper

multicolor offset printing.

from discoloration and deterioration over time. Alkaline pH

For an illustration of how the environment, visit

to process, is naturally acid free and can be recycled. One-hundred-

paper.7 Although uncoated

54% less solid waste

your paper choices affect

lignin than trees, kenaf requires fewer chemicals, takes less energy

coated paper than uncoated

33% less waste paper

brightness. The U.S. Environmental Protection Agency and the

Environmental Commitment (Inside Back Cover)

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Paper | Sources • 7

Sustainable Forestry Initiative* (SFI) | A comprehensive forest management/reforestation program that balances the demand for wood products with the need for forest sustainability. Developed

FSC 100% | Material comes from forests certified as

Forest Stewardship Council.

SFI logo | The Sustainable

Sustainable Forestry Initiative combines environmental responsibility

Forestry Initiative employs an

with sound business practices. Providers of wood and paper prod-

on-product SFI logo, or label,

ucts, member companies plant over a million acres of trees per year.

available for use by participat-

Participation in the program is a condition of membership in the

ing companies. The SFI Office

Paper | Pulp Sources

American Forest & Paper Association. The SFI program is overseen

of Label Use and Licensing

by the Sustainable Forestry Board, an independent nonprofit organi-

must approve each com-

One of the challenges for graphic professionals has been to identify

zation responsible for maintaining and verifying SFI standards.

pany that uses an SFI logo. For

4

meeting the environmental and social standards of the

in 1994 by the American Forest & Paper Association (AF&PA), the

and verify environmentally responsible pulp and paper sources. This changed in the 1990s with organizations whose goal was to certify that member companies met established sustainable forestry FSC Recycled | Post-consumer reclaimed material includes wood fiber reclaimed from a product that has been used for its intended end use.

standards. Two of those organizations are the Forest Stewardship Council and the Sustainable Forestry Initiative. Designers can be assured that their paper comes from a responsible source if it is FSC- or SFI-certified. Abundant Forests Alliance | Composed of members of the North American wood and paper products industry. The alliance’s goals are to manage the delicate balance between supplying wood and paper products; maintaining healthy, abundant forests; and protecting trees, soil, air, water and wildlife habitats. The group advocates sustainable forest practices, such as harvest-

FSC Mixed Sources | Material comes from FSC-certified

ing and replanting, as well as recycling. Forest Stewardship Council* (FSC) | The presence of

forests, company-controlled

the Forest Stewardship Council chain-of-custody logo ensures that

sources and/or post-consumer

the materials used to produce the product or printed piece were

reclaimed material.

sourced responsibly. Every entity that touches the product—from the logger to the printer—must be FSC certified. Designers and printers who wish to use the FSC logo or would simply like more information may contact the FSC at www.fsc.org.

Rainforest Alliance logo |

Rainforest Alliance | The Rainforest Alliance works with

Indicates that the products

FSC to help companies incorporate sustainability into their sourc-

have come from agricultural

ing strategies. It ensures that wood products do not negatively im-

or forestry businesses that are

pact indigenous populations, come from conservation areas, come

managed in accordance with

from genetically modified trees and are not illegally harvested. For

strict standards for social and

more information about the Rainforest Alliance, the Smartwood

environmental sustainability.

program and its overall mission, visit www.rainforest-alliance.org.

information about the labeling * Third-party audit is required for certification Environmental Commitment (Inside Back Cover)

program and the criteria for use, visit www.aboutsfi.org.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Paper | Manufacture • 9

On-Site Generation | A few paper mills use green power by actually producing their own renewable energy on site. This is accomplished in most cases by “low-impact” hydroelectric genera-

Paper | Energy and Emissions When thinking about paper, another consideration is to buy from sources that use renewable energy in production. Each year more and more paper manufacturers make the claim of green power when discussing the energy used to power their plants. Literature

produce electricity. Unlike the large-scale hydroelectric operations of the past, low-impact hydroelectric preserves the flow of a river, allowing it to maintain healthy oxygen levels while also allowing fish migration to occur. On-site generation has one immediate advantage over RECs because it lowers the demand on the power grid.

from most major paper mills would seem to indicate that virtually

Energy and Emissions | One of the many advantages of

every manufacturer is entirely off the energy grid and has a wind

renewable green energy is that it produces far fewer polluting

farm next door supplying it with all the clean power it requires.

emissions than traditional fossil-fueled power. It dramatically

This is the exception rather than the rule. So how can paper

reduces carbon emissions. Wind, hydroelectric, solar and geother-

manufacturers make such claims? In general, there are three ways

mal power sources all generate little if any carbon emissions after

that paper manufacturers (or anyone else) can make a claim of us-

the emissions created by building the initial infrastructure are ac-

ing “renewable energy.” One is by purchasing green power directly

counted for. Though some green energy methods, such as biomass

from a renewable energy power plant. The second is by purchasing

fuels, use combustion and therefore release carbon, they still emit

Renewable Energy Certificates and the third is by generating their

far less pollution than their coal and oil counterparts.

own renewable energy on site.11

Green-E | The Green-e logo

tion. Turbines are placed on an adjacent river to turn generators that

Carbon Neutrality | As a response to global climate

Most mills that create

Direct Purchase | Manufacturers with facilities whose elec-

change and its impact on consumer behavior, manufacturers, cor-

renewable energy on site

trical grid is fed by green-power plants may be able to purchase

porations, government entities and even individuals are looking for

also need to supplement their

energy directly from the utility. Electricity suppliers offer these

ways to become “carbon neutral”. They are taking actions to reduce

power needs. Those wishing

products either as a percentage of electricity usage or in a fixed

atmospheric carbon emissions in proportion to those generated by

to claim “100% green power”

number of units or blocks of kilowatt-hours.

their activities in business and daily life. This is generally accom-

accomplish this by supple-

plished in two ways: lowering carbon emissions directly by lower-

menting their on-site genera-

ing consumption and by promoting activities that aid the natural

tion with RECs or direct green

process of carbon reduction such as preserving wilderness areas.

energy purchases from a utility.

Renewable Energy Certificates | The way most paper

indicates use of certified

mills achieve the claim of green power is through the

renewable energy. Green-e is

purchase of Renewable Energy Certificates. Renewable Energy

the nation's largest independent

Certificates provide a subsidy to designated renewable energy

certification and verification

sources such as wind, solar, geothermal, hydro-electric and biomass

credits is based on trading carbon emissions as a commodity. Under

program for renewable energy.

power plants. The theory behind REC’s is that by providing a

these programs an entity that produces emissions beyond an allotted

Eligible sources of supply

subsidy to renewable energy producers, it will make them more

level, must purchase emissions credits to offset their activity from

include solar electric, wind,

competitive in the energy market. This will allow them to sell

an entity that either produces less than their allotted amount, or

geothermal, low-impact

energy at closer to local market rates and encourage renewable

promotes activity that results in emission reduction. The incentives

hydroelectric, biomass,

energy use and growth versus less expensive fossil fuel or nuclear

are financially based, rewarding those who lower or reduce emissions,

biodiesel and hydrogen fuel

based power sources. Many companies, environmental organiza-

while penalizing those who exceed their quotas. The emission credits

cell technology. For more

tions and government bodies see REC subsidies as a long-term

are currently traded throughout European markets and through the

information about Green-e

method of growing the renewable energy infrastructure. Third par-

Chicago Climate Exchange (CCX) www.chicagoclimatex.com.

certification for renewable

ty certification by organizations such as Green-e and the Climate

energy, visit www.green-e.org.

Neutral Network ensure a valid source of supply.

Carbon Offset Credits | The concept of carbon offset

Environmental Commitment (Inside Back Cover)

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Paper | Manufacture • 11

EPA Programs | The Environmental Protection Agency has several partnership programs, each with a corresponding logo. Of note to eco-oriented designers are the Performance Track Program, the Climate Leaders Program and the Green Power Partnership program. Partners may use the respective logos of programs they qualify for by meeting prescribed criteria. The Green Power Partnership is a voluntary program designed to support the increased use of green power among leading U.S. organizations, in order to reduce the environmental impacts associated with fossil-fuel electricity use. Partners commit to purchase an amount of green power that is proportional to their annual electricity consumption. Eligible renewable resources include wind, solar, geothermal,

Paper | Environmental Programs It should be noted that carbon

ISO 14001 Certification | The International Organization

qualifying biomass and low-impact hydropower. Purchase require-

Green Seal | The Green

ments may be met with green power products, renewable energy

Seal logo may be used by

certificates (RECs), power from on-site generation, or any combina-

products that pass Green

tion of the three. Minimum purchase requirements must be met with

Seal certification. Green Seal

power from “new” renewable facilities. Participants that have met

is an independent, non profit

all criteria may use the Green Power Partnership logo. Similar to the

organization whose goal is

Green Power Partnership Program, the Green Power Leadership Pro-

to promote sustainability by

gram is a higher level of commitment to the procurement of renew-

identifying and promoting

able energy credits. Commitment is defined as a minimum of 20% of

environmentally preferable

a "leader’s" total electrical load. For the largest electrical consumers,

products and services. Green

the amount can be as high as 40%. For additional information on

Seal has developed environ-

these EPA programs, visit www.epa.gov.

mental leadership standards

Performance Track Programs are voluntary partnership pro-

offset programs have stirred

for Standardization (ISO) is a network of the national standards

controversy. Critics claim that

institutes of 157 countries that sets international business and

the programs allow polluters

manufacturing standards. ISO 14001 is a standard for environmen-

to purchase their way out of

tal management. Companies attaining an ISO 14001 certification

eco-unfriendly practices while

have developed both a comprehensive system to minimize harmful

claiming carbon neutrality.

effects on the environment caused by manufacturing, and a process

Proponents claim that the

to continually improve environmental performance. Before a certi-

programs encourage carbon

fication is issued, compliance to the standard is verified by an inde-

reduction and carbon reduction

pendent auditing organization. Though ISO has no internationally

Climate Leaders Programs are industry-government partnership pro-

awareness on a large scale.

recognized logo, companies that have been certified may either use

grams that develop long-term comprehensive greenhouse gas (GHG)

their own logos with the full ISO designation (e.g., ISO 14001:2004)

reduction strategies. Participants set a reduction goal, inventory their

or ask their certifying body for permission to use the certifier’s logo

emissions to measure progress and report their progress in data form

with the designation. For a list of certifying organizations or more

to the EPA. Participants enrolled in the program may display the

information about ISO 14001, visit www.iso.org.

Climate Leaders logo.

grams that recognize and reward private and public facilities that demonstrate strong environmental performance beyond current requirements. Partners must consistently meet environmental legal requirements, have voluntarily made unregulated environmental improvements and have implemented environmental management systems that are subject to third-party audit. Another component of the program is environmental public outreach.

Environmental Commitment (Inside Back Cover)

for several categories, including printing and writing paper. Criteria for certification include that papers contain at least 30% post-consumer material or be manufactured without chlorine or chlorine derivatives. Additional information about Green Seal certification can be found at www.greenseal.org.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Production • 13

Production Environmental conscientiousness includes every step in the process of getting a printed piece into the hands of end users and beyond. Once print options are chosen, but before printing actually begins, steps can be taken for production to minimize chemical and paper waste.

Some efficient uses of standard-size press

Optimum sheet use | Work closely with the printer early in the

sheets (assuming light-

planning process. Parent sheets of paper typically come in several

to-medium-coverage color

standard sizes. Designers can size their projects to make more

work). It is best to work

efficient use of standard sheet sizes—printing two-, three-, or

directly with your printer

four-up (or more) to use less paper and to minimize the amount

early in planning, as

of waste. When making comps, designers can request the use of

press needs vary.

double-sided, smaller, reused, or recycled paper.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Production • 15

Smaller saves | Rethinking size in general is a good place to begin. Can a smaller piece serve the same purpose and have as much impact as a larger piece? Large or odd-sized designed pieces may not use paper efficiently and can result in substantial amounts of waste. Reducing size not only minimizes waste and energy consumption, but also saves money. Less complexity equals less waste | Simplifying a piece can also reduce waste. Complex folding specifications can use more paper, resulting in more waste. For example, while elegant, a french-folded book uses twice the paper necessary, as it is composed of sheets with printing on one side, folded to reveal the printed side only. Sometimes, reducing complexity might be as simple as adjusting the size of a pocket or folded section. Combine jobs | Ganging multiple print jobs uses less paper. By working with their printer early in the conceptual stage, designers creating multiple pieces with the same paper stock and ink can combine similar print jobs in the same print run. Ganged print runs reduce paper use, decrease the number of press make-readies, use fewer printing plates and save money. Digital photography | The advent of digital cameras has drastically reduced waste output. Gone are the developing chemicals and the celluloid negatives. Paper is considerably reduced or eliminated entirely. However, not all digital photography is equal— care must be taken to ensure high resolution and quality. Digital proofing and file delivery | The electronic

For print jobs of sufficient quantity, designers can custom-order a sheet size

technology of the PDF (portable document format) can save not

Evaluating your print-

only resources but also time. Delivering art directly to the printer

design practices from

via PDF and/or server uploads eliminates wasted storage media.

an ecological standpoint

On-screen proofing, via PDF, eliminates paper waste.

can result in the added

• Can the piece

benefits of increased

serve more than

effectiveness and cost

one purpose?

efficiency.

Can a poster series

• Would an alternative

that meets the specifications

typeface or document

of their design—significantly

layout increase leg-

reducing or eliminating paper

ibility while decreas-

waste and saving money.

ing page count?

be double-sided? Can a brochure double as a poster? • Can a mail promotion become a self-mailer?

• Can specific content be omitted from a

• For mailings, can

bound piece and

the size, aspect

inserted into a back

ratio, or weight be

pocket for a targeted

optimized for lower

audience?

postage rates?

Bleeds can give design an increased impact; they can also impact the waste stream. Designs with bleeds are printed on oversized sheets and then trimmed to finish size. This not only increases the number of paper sheets but also increases the amount of trim waste. Consider downsizing to allow for trim on bleeds without upgrading to an oversized sheet of paper.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Inks From a green standpoint, two factors to consider when researching ink options are the effect on the environment of the printing process and the recyclability of the finished piece. The areas of concern are volatile organic compounds, non-renewable resources and heavy metals used in pigments. Designers may want to discuss ink options with their printer with these factors in mind. Cost is, of course, another important factor; any opportunity to reduce ink usage also saves money. Petroleum-based inks | These contain ozone-damaging distillates and volatile organic compounds (VOCs), with heat-set web offset inks emitting the most. (Many of these pollutants can be eliminated through catalytic converters.) In addition, petroleum is not a renewable resource and is not considered environmentally sustainable. Consider using fewer ink colors, perhaps two instead of four. Four-color printing involves four metal printing plates and four separate inks. Attractive alternative designs can be made with effective use of spot colors. In addition, reduce full-page ink floods—more ink means more de-inking. De-inking is the process by which inks, adhesives, glues, staples and other non-paper elements are removed from

Vegetable oil-based inks | These can be an effective alternative. Often referred to as “agri-based inks,” they are well suited for uncoated paper due to their low VOC content. Biodegradable, they are made with renewable resources, such as soy, linseed, cottonseed, tung, or china wood oil. The soy or vegetable content may vary, typically from 20% to 100% of the oil in the formulation, with the remainder being petroleum.12 Although agri-based inks may contain petroleum, they don’t have the VOC levels found in solvent-based formulations, which can be as high as 25–40%.13 It should be noted that there are no minimum percentages of soybean oil required to use the American Soybean Association’s soy logo. Because of the variations and content of VOCs, designers will want to check with their printer about soybean oil content and insist on a low VOC rating.

recovered paper. De-inking

Recycled inks | These can also lessen the environmental impact

raises some concern because

of printing. Inks are not recycled in the same way as paper, plastics,

the byproduct is waste sludge

or glass. Some printers can reuse old or spent inks by blending them

that must be disposed of. Less

together. Otherwise, such inks may be returned to ink distributors

ink has less of an impact on

or disposed of through a registered disposal company. It should be

the environment.

noted that color quality can vary greatly when using recycled inks.

Color • 19

Heavy metals | Some pigments contain heavy metals.

Even vegetable-based inks

Although such known carcinogens as lead, chromium and

are harmful if they exceed

cadmium have been replaced with carbon-based substitutes, some

EPA threshold levels of copper

pigments still contain barium, copper and zinc. For a greener choice,

and/or barium. Metallic

designers can discuss with their printer which colors do not contain

inks and fluorescent inks,

heavy metals and what alternative pigments can be found to match

particularly greens, oranges

the desired color. In general, fluorescent and metallic inks are more

and opaque yellows, have

toxic, because they contain heavy metals. Although some materi-

some of the highest levels

als printed with metallic ink may be recycled, they are not easily

of carcinogens.

decomposed and the heavy metal component can be hazardous to groundwater.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Printing • 21

Printing The offset printing industry has made great strides in develop-

Digital printing is well suited

ing and implementing products and processes that are friendlier

for short runs and quick turn-

to the environment. By partnering with printers whose practices

arounds. Efficient quantities

promote environmental sustainability, designers will be able to

are fewer than 1,000 and typi-

explore all the available options. Selecting the right printer and the

cal sheet sizes no larger than

right process will influence not only the quality and environmen-

12 x 18. Four-color, market-

tal impact but also the cost of a project.

targeted items like brochures,

Lithography (offset printing) | Lithography accounts for more than 50% of the commercial print industry.14 It is a process by which the art, or graphic content, is transferred to a printing plate. The plate is coated with ink and fountain solution (98% water), and the image is then transferred to a rubber blanket before being printed on paper. In recent years, the offset printing industry has shifted away from the solvent-based products of the past to ones that have the least impact on the environment. Printers are now using alcohol-free substitutes that use glycol15 during the plate-making process, soy- and vegetable-based ink during the printing process (with the exception of heat-set web offset), low-VOC, water-miscible solvent blanket washes during press cleanup and disposal of any chemicals through EPA-licensed hazardous-waste-disposal companies. Digital imaging | Toner-based digital printing, often referred to as “print on demand,” is the least environmentally invasive. Because all graphic content is in electronic form from creation through printing, the chemicals associated with film processing and plate making are eliminated, as is make-ready waste. The toner is non toxic and biodegradable. The digital process is flexible, allowing for small-quantity, on-demand print runs that reduce inflated inventories and ultimately reduce stockpiles of obsolete printed materials.

flyers, postcards and promotional pieces are typical candidates for this process.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Waterless printing | The waterless process eliminates the fountain solution, or dampening system, used in offset lithography, both web and sheet fed. Instead of conventional metal printing plates, this process uses a multilayered silicone rubber plate and special ink. The process is faster and cleaner, with reduced paper and energy waste.16 Beyond mere VOC reduction, this process is said to really shine in providing high quality and efficiency with low dot gain for enhanced detail, better color saturation and faster make-readies. Varnish | Varnishes, both matte and gloss, come in petroleumbased and water-based versions. Press-applied varnish typically is solvent based and emits VOCs. Aqueous-based varnishes, a mix of polymers and water, emit fewer VOCs, do not require solvents for cleanup, and can be recycled and repulped. They are the most economical and environmentally friendly. As with inks, the less varnish that is applied to the sheet, the better for the environment. UV inks and coatings | Touted for their beauty and durability, UV formulations are printed as a paste/liquid and immediately change to a solid film when exposed to ultraviolet light energy, releasing no VOCs or solvents into the air. This process involves such special equipment as UV lamps for energy, reflectors to intensify the light and cooling systems for the lamps, as well as special safety equipment and precautions for the press crews. Although the process has been questioned for its recyclability, a study by the Beloit Corporation of Wisconsin has proven that paper printed with UV ink and coatings can be repulped, de-inked and recycled.17

Varnish is applied to protect the printed surface. The less ink coverage, the less varnish, if any, need be applied. Spot varnish on only the heavily inked areas is an alternative to a flood coating of varnish.

Printing • 23

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Finishing • 25

Finishing Designers who have taken the trouble to choose environmentally sustainable paper, low-VOC ink and a design that minimizes paper waste will want to be sure that all their efforts are not wasted through finishing techniques that hamper the ability of their projects to be recycled. Saddle stitching | Metal staples that are used in binding do not need to be removed for recycling in most municipalities. Staples are removed at the recycling pulp mill using magnets, screens and filters during the repulping process. Although the staples are not themselves recyclable, this is still a good option. Perfect-bound adhesives | In order for perfect binding to be recyclable, all adhesive residues must be removed from the paper fiber. Hot-melt, petroleum-based glues are hard to remove during de-inking. Water-based, non-chlorinated glues, however, break down easily during the recycling process. Wire rolls and plastic combs | Both wire rolls and plastic combs are recyclable as long as they are separated from the printed pieces. Consider including a note to end users on the printed piece with instructions on how to recycle. Embossing | Using no chemicals or inks, this technique of creating a raised or receding image is an environmentally friendly way to add dimension. The die can be reused and it also works beautifully on uncoated paper. Die cutting | In this method, the die acts like a cookie cutter. Similar to embossing, there is no use of chemicals or inks and the die can be reused. This is another environmentally friendly way to achieve a dramatic effect that works well on uncoated paper.

Consider working with an

Engraving | The complicated engraving process involves etching de-

FSC-chain-of-custody-

signs into dies, inking the dies and pressing the die to paper. This classic

certified printer. The

and typically costly technique imparts elegance with minimal environ-

Forest Stewardship Council

mental impact, as most engraving inks are water- or vegetable-based.

ensures environmental

Foil Stamping | Foils are a polyester film coating that impart a

accountability by tracking

polished look with various finishes from matte to metallic. Although not

wood or fiber from its

all foils use toxic chemicals, they still pose a challenge, as they don’t break

origin through shipment

down in the de-inking process and may make paper unrecyclable.

to the customer.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Packaging • 27

Make It Smaller | Designers intent on pursuing eco-friendly packaging options need to look first at the attribute that can have the most immediate impact: size. While oversized packaging was once considered to be a good way to gain more visibility on the shelf, today’s eco-oriented consumers see oversized and overpacked items as wasteful. Designing a product’s packaging to be more in line with the product size dramatically reduces the amount of packaging waste. It also increases the perceived value of the product. Design it to Last | Although it might seem a bit counterintuitive, another way to make packaging eco-friendly is to design it to last. Packages themselves can become keepsakes if they are attractive and durable enough to provide an alternative use. Similarly, packaging for nonperishable products can be designed to be an appealing and efficient storage method for the product throughout its useful life. Package longevity can also be encouraged by building convenience features into the package design. Features such as hang tabs for easy storage, contours that aid in stacking and insets that provide a base for more unsteady products can all add to a package’s lifespan. Paper or Plastic? | The choice of materials can greatly influence a package’s impact on the environment. Choosing packaging components that are made from recycled materials is a good way to start. Materials also need to be considered in terms of the amount of energy required to create them and the amount of waste and pollution created during their manufacture. Other considerations include a material’s level of biodegradability and how easily and likely it is to be recycled. Last but not least is whether or not a material comes

Packaging While all of the paper, inks and finishing techniques reviewed in prior chapters of this guide can also be applied to packaging, there

from a sustainable resource. Material

Sustainable Source

Energy to Manufacture

Energy to Recycle

Aluminum cans

No

Very high

Moderate/low

PET plastic

No

Very high

Moderate

LDPE plastic

No

High

Moderate

HDPE plastic

No

High

Moderate

Steel cans

No

Moderate

High

Paperboard (bleached)

Yes

Moderate

Low

Bleached corrugated cardboard

Yes

Low

Moderate/low

waste stream consists of packaging. As a result, designing

Paperboard (unbleached)

Yes

Low

Low

packaging with the environment in mind can dramatically

Unbleached corrugated cardboard

Yes

Low

Low

Glass

No

Low

Low

are additional considerations to take into account when designing packaging to be as eco-friendly as possible. According to the Environmental Protection Agency (EPA), as much as a third of the developing world’s non-industrial solid 18

impact energy use and the waste stream overall.

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Think Inside the Box | Packaging size and waste can be reduced by placing instructions, warranty information and less purchase-relevant information on inserts that fit inside the package. This can reduce the area needed on package exteriors to convey this information. Another way to reduce the amount of packaging needed to convey information is to print the information on the inside of the package and design it to be disassembled. The method used to protect products can dramatically improve a project’s environmental impact. For fragile products that require added protection, consider recycled pulp-based molded inserts and water-soluble, cornstarch-based packing materials instead of molded and loose polystyrene. If the materials inside the package are made from the same or similarly based materials as the package itself, it is more easily and more likely to be recycled. Shipping savvy | The sizes and shapes of individual packages directly impact the efficiency and amount of outer carton materials required to get packages to market. As much as 50% of packaging waste can occur in outer carton packaging that a consumer or end user will never see. Savvy designers know how many packages are intended to be shipped at once, how the packages will be displayed when in store, and for smaller runs, what standard outer carton sizes are available. This information allows them to design for the most efficient packing in addition to packaging. Shape also affects outer packaging material requirements. Round or cylindrical packages are less efficient to ship in bulk, as outer shipping cartons are rectangular. A general rule of thumb is that the more voids there are inside a shipping carton when packed, the more waste there is in outer carton materials. The use of prepacks can also reduce waste. Often outer shipping cartons can be designed to work as in-store displays, eliminating the need for added merchandising materials.

Packaging

• 29

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Checklist • 31

Checklist Planning

Production

Inks & Finishing

Printing

Logo Use

Other

Consider 100% PCW,  uncoated paper

Carefully target your audience to maximize print effectiveness along with other media options

Consider vegetable-based inks 

Involve the print vendor in the  planning stages

Use recycled logo and indicate PCW content

Use  “energy saver” features on computer equipment

Choose an FSC-certified printer

Use “FSC” or “SFI” logos according to guidelines

If not FSC certified, check that the printer has an environmental management system in place

Indicate ISO certification where applicable

Institute an office recycling program and promote the purchase of recycled office paper

Consider Elemental Chlorine Free or Totally Chlorine Free paper If using virgin paper stock, consider one that has FSC or SFI certification Buy  paper from a source using sustainable energy in production  long shelf life, choose a For paper that meets the American National Standards Institute standards for product longevity Plan ahead to avoid air and rush shipping. Use targeted, updated mailing lists

Use the fewest materials necessary to be effective Maximize long-term value with useful, multipurpose design If  the printed piece isn’t reusable, ensure that it is recyclable Use  digital photography  PDF digital proofs in place Use of paper printouts

Use fewer ink colors Consider less ink coverage Avoid metallic and fluorescent inks when possible Consider using aqueous varnishes and coatings instead of UV coatings and laminates Consider alternatives to  foil stamping Consider water-based glues

Consider filmless and plateless  digital printing for small runs Send art to printer electronically or on a rewritable CD (to be returned) Clearly outline specs to vendor At project close, recap with client and vendors to learn from successes or failures

Use PCF, ECF, or TCF des ignations where appropriate according to pulp-bleaching method Note vegetable ink use   Encourage end user to either share or recycle the printed piece

Print double-sided and/or in draft mode Use  silverware and mugs instead of paper and plastic Donate old office equipment  to schools Shake toner cartridges occa sionally to lengthen life Use alternative modes of transportation

1. American Forest and Paper Association, “Environment & Recycling,” www.afandpa.org. 2. C  onservatree, “Making Paper: Production,” www.conservatree.org/learn/Essential%20Issues/EIPaperMaking.shtml. 3. Poppy Evans, The Complete Guide to Eco-Friendly Design (Ohio: North Light Books, 1997), 18. 4. Conservatree, “Making Paper: Content.” 5. Poppy Evans, The Complete Guide to Eco-Friendly Design, 16. 6. Poppy Evans, The Complete Guide to Eco-Friendly Design, 14. 7. Design by Nature, “Recycling Process,” Guide. www.designbynature.org/main.php. 8. Environmental Defense, www.environmentaldefense.org. 9. American Forest and Paper Association, www.afandpa.org. 10. Sustainable Forest Initiative, “About SFI,” www.aboutsfi.org/about.asp. 11. EPA "Guide to Purchasing Green Power,” www.epa.gov.

Charley Harper

12. Solid Waste Management Coordinating Board, www.swmcb.org.

This second edition of A Field Guide: Eco-Friendly, Efficient and Effective Print is dedicated to Charley Harper whose six decade career of capturing the natural world in illustrations are featured throughout its pages. Charlie was an American original—both artist and conservationist and had been called "The Audubon of his time." He was beloved for his delightful, graphic and often humorous illustrations of nature, animals, insects and people alike. When asked of his minimalist style, Charley liked to say that when he paints a bird, he doesn’t count all the feathers in the wings, he just counts the wings. He was best known for his illustration work in The Ford Times, The Golden Book of Biology, Betty Crocker’s Dinner for Two Cookbook, as well as numerous posters for the National Park Service and the National Audubon Society. Charley passed away at age 84 on June 10th 2007 while this guide was in production. A compendium of Charley’s work, Charley Harper: An Illustrated Life designed by Todd Oldham, was released in summer 2007 through Ammo books.

13. Poppy Evans, The Complete Guide to Eco-Friendly Design, 23. 14. U.S. Environmental Protection Agency, www.epa.gov. 15. American Forest and Paper Association. 16. Design by Nature, “Printing Methods.” 17. R  adTech Intl. North America. “UV/EB Printed and Coated Paper,” http://www.radtech.org/SustainableSolution.htm. 18. EPA “Product Stewardship/Packaging,” www.epa.gov.

Bibliography American Forest and Paper Association, www.afandpa.org. ---, “Environment & Recycling.” www.afandpa.org.  onservatree, “Buyers: Consumers Are Key.” C www.conservatree.org/learn/Essential%20Issues/EIPaperMaking.shtml. - --, “Making Paper: Content.” www.conservatree.org/learn/Essential%20Issues/EIPaperMaking.shtml. - --. “Making Paper: Production.” www.conservatree.org/learn/Essential%20Issues/EIPaperMaking.shtml. Design by Nature. “Printing Methods.” Guide. www.designbynature.org/main.php. ---. “Recycling Process.” Guide. www.designbynature.org/main.php. Environmental Defense Fund. www.environmentaldefense.org. Evans, Poppy. The Complete Guide to Eco-Friendly Design (Ohio: North Light Books, 1997), 18. Forest Stewardship Council. www.fsc.org.  insella, Susan. “The History of Paper.” Conservatree. K http://www.conservatree.org/learn/Papermaking/History.shtml. Minnesota Environmental Initiative. “Print Buyer Guide.” www.mn-ei.org/policy/printbuyer.html.  aper Industry Association Council (2006). P www.paperrecycles.org/paper_environment/index.html. RadTech Intl. North America. “UV/EB Printed and Coated Paper,” http://www.radtech.org/SustainableSolution.htm. Solid Waste Management Coordinating Board. www.swmcb.org. Sustainable Forest Initiative. “About SFI.” www.aboutsfi.org/about.asp. University of Melbourne. “Little Green Guide to Printing and Design.” www.mpso.unimelb.edu.au. U.S. Environmental Protection Agency. www.epa.gov. Waterless Printing Association. www.waterless.org. Disclaimer: Information for this brochure was obtained from the best sources available at the time of printing.

All Monadnock’s Graphic Arts and Packaging Papers are made with 100% renewable electrical energy. All Monadnock’s Graphic Arts, Printing and Packaging Papers are manufactured Carbon Neutral. Monadnock is the only premium uncoated text and cover paper mill in the United States with a certified

Envi by Monadnock®

Astrolite pc100®

Astrolite®

Dulcet®

Caress®

Made with 100% Green Electricity

l

l

l

l

l

Green-e / EPA Green Power Leadership

Manufactured Carbon Neutral

l

l

l

l

l

ISO 14001: 2004/SGS/ Environmental Resource Trust

Environmental Management System

l

l

l

l

l

ISO 14001:2004/ SGS/EPA Performance Track

Responsibly Sourced Fiber

l*

l*

l

l

l

CSA/FSC/ PEFC/SFI

Solid Waste Reclaimed/ Recycled

l

l

l

l

l

ISO 14001: 2004/SGS/ EPA WasteWise

Process Chlorine Free

l

l

l

l

l

ISO 14001:2004/ SGS/Supplier Documentation

l

l

l

ISO 14001:2004/ SGS/Supplier Documentation

Authority &/or Certifier

ISO 14001:2004 Environmental Management System. All Monadnock’s recycled papers are FSC Certified. Monadnock only buys pulp from suppliers who prove it was sourced responsibly. Monadnock continuously reduces the amount of resources it consumes in manufacturing even as its production increases. Monadnock’s solid waste is recycled and reclaimed for uses that actually green the environment. All Monadnock’s Papers are Process Chlorine Free.

Elemental Chlorine Free

Post-Consumer Recycled Content

l

l

*Astrolite PC100 and Envi by Monadnock are FSC certified.

FSC/Smartwood

TRIM

References

Monadnock Paper Mills | Environmental Commitment

Monadnock Paper Mills A Field Guide: Eco-Friendly, Efficient, and Effective Print

Reference • 35

Published By Monadnock Paper Mills, Inc.

Artwork All images ©2007 Charles Harper and his respective clients.

In 2006, Monadnock Paper Mills’

Design

renewable energy production

Signaltree Marketing & Advertising | Keene, NH | 603-358-5100 | [email protected]

had environmental impact of

Special Thanks

• 1,200 cars not driven for 1 year

Brett Harper, Todd Oldham and Kelly Rakowski

• 11,041 barrels of oil saved

Printing Specifications

• 120,322 tree seedlings grown

This brochure was printed on a Heidelberg xl-105, a 28" x 40" 8-color press. The book was run as two sheetwise forms. The tone reproduction curves were adjusted to enhance various details of the images. All images were printed in 4/c process, using Sun Chemical Soy-Based Inks. All screen resolutions are 175-line. An overall satin aqueous coating was run on all forms.

© 2007 Monadnock Paper Mills, Inc. 117 Antrim Road Bennington, New Hampshire 03442-4205 603.588.3311 www.mpm.com

improvements equal to:

for 1 year • 41 acres of forest preserved We generated 49% of our electricity from our hydro-electric turbines in 2006.

TRIM

Paper Credit The Second Edition of A Field Guide: Eco-Friendly and Efficient Print is printed on Monadnock Astrolite pc 100® 80 lb. text and 80 lb. cover. Monadnock Astrolite PC100® 100% Post-Consumer Recycled Material—Monadnock Astrolite pc 100 uses post-consumer fiber from waste sources that are carefully selected and controlled, creating a paper with the highest levels of consistency, brightness and cleanliness.

We’ve doubled our purchase of post-consumer reclaimed material in 3 years. (2004-2006)

Monadnock utilizes on-site low-impact hydroelectric power and Green-e® Certified Renewable Energy: green-e.org | Carbon Neutral Manufacturing | SW-COC-1160 ©Forest Stewardship Council A.C. and the Rainforest Alliance ensure responsible use of forest resources | Certified ISO9001:2000 for Quality Management System | Certified ISO14001:2004 for Environmental Management System

ANSI Archival Compliance All Monadnock papers are alkaline pH and buffered for longevity. Each features superior formation; a smooth, level surface; excellent opacity; and exceptional side-to-side uniformity. All are made to the American National Standards Institute (ANSI) standards for paper longevity.

We’ve decreased trash sent to landfills by 80% in 2 years. (2005-2006)

ISO 9001: 2000, ISO 14001: 2004 For information, see page 10 and back cover.

®

Monadnock Astrolite, Astrolite pc 100, Dulcet, Caress and Envi by Monadnock are registered trademarks of Monadnock Paper Mills, Inc. All trademarks and copyrights are the property of their respective owners. Printed in usa. 7.07 ©2007 Monadnock Paper Mills, Inc. Please keep, share, or recycle Environmental Commitment: The Monadnock logo throughout the book denotes those programs to which Monadnock subscribes.